Some updates from to this thread since I last posted with my new discoveries.
1) Was able to get key made. Yes they need to be programmed. A local locksmith had a similar key which he cut and programmed from my one existing key. Now I have 2
2) Still not able to find body panels but I have a green and white set so I am good for now and I can always have them painted.
3) Replaced Stock Delta 60mm fans with another set of Delta fans. I was concerned about proper CFM (airflow) and heat with new fans so I went with another model of Delta that were 20DB less but airflow 45 CFM. No issues with charging or heat and it is very noticeably quieter when charging.
4) Still using 14 gaugh high quality extension cord -- no issues.
Main engine cooling fan is still loud but I don't think I could replace it with another that would cool the engine as efficiently. No sure what else I could better air cool the motor, so for now loud motor fan has to stay.
I added LED light from amazon (
http://www.amazon.com/gp/product/B00PNKHW4E?psc=1&redirect=true&ref_=oh_aui_detailpage_o02_s00). I really like the improvement in brightness. I am not sure it improves how much more I see over the stock light however, I think it greatly improves my visibility to other drivers because it is so bright even in the day time -- so that is worth it.
Thanks much